Skoda Octavia II 2004 Instruction manual

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Workshop Manual
Octavia II 2004 ➤
Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine
Engine ID BKD AZV BMM
Edition 01.2018
Service
Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2018 ŠKODA AUTO a. s. S0057090020

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Additional instructions when undertaking assembly work on the air-conditioning system . . 2
1.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety precautions when working on the diesel direct injection system . . . . . . . . . . . . . . . . 3
1.5 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 4
1.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Unit mounting - tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.5 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2 Removing and installing toothed belt for engines with code BKD, AZV . . . . . . . . . . . . . . . . 26
1.3 Removing and installing toothed belt for engines with code BMM . . . . . . . . . . . . . . . . . . . . 38
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Replace crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 51
2.3 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.4 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.5 inspect piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.1 Summary of components for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . 69
1.2 Removing and installing cylinder head cover for engines with code BKD, AZV . . . . . . . . . . 72
1.3 Removing and installing cylinder head for engines with code BKD, AZV . . . . . . . . . . . . . . 73
1.4 Checking the compression pressure for engines with code BKD, AZV . . . . . . . . . . . . . . . . 81
1.5 Summary of components for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.6 Removing and installing cylinder head cover for engines with code BMM . . . . . . . . . . . . . . 83
1.7 Removing and installing cylinder head for engines with code BMM . . . . . . . . . . . . . . . . . . 85
1.8 Checking the compression pressure for engines with code BMM . . . . . . . . . . . . . . . . . . . . 93
2 Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine - Edition 01.2018
Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2.1 Summary of components for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . 95
2.2 Checking the axial play of the camshafts for engines with code BKD, AZV . . . . . . . . . . . . 97
2.3 Replacing the sealing rings for camshafts for engines with code BKD, AZV . . . . . . . . . . . . 97
2.4 Removing and installing camshafts for engines with code BKD, AZV . . . . . . . . . . . . . . . . 98
2.5 Removing and installing valve levers for engines with code BKD, AZV . . . . . . . . . . . . . . . . 105
2.6 Checking the hydraulic supporting elements for engines with code BKD, AZV . . . . . . . . . . 107
2.7 Replacing valve stem seals for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . 108
2.8 Valve dimensions for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.9 Summary of components for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.10 Checking the axial play of the camshaft for engines with code BMM . . . . . . . . . . . . . . . . 112
2.11 Replacing the sealing ring for camshaft for engines with code BMM . . . . . . . . . . . . . . . . . . 113
2.12 Removing and installing the camshaft for engines with code BMM . . . . . . . . . . . . . . . . . . 115
2.13 Checking the hydraulic bucket tappets for engines with code BMM . . . . . . . . . . . . . . . . . . 118
2.14 Replacing valve stem seals for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.15 Valve dimensions for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2.16 inspecting valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.1 Disassembling and assembling the oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.4 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Removing and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.1 Parts of the cooling system fitted to body for engines with code BKD, AZV . . . . . . . . . . . . 129
1.2 Parts of the cooling system engine side for engines with code BKD, AZV . . . . . . . . . . . . 131
1.3 Connection diagram for coolant hoses for engines with code BKD, AZV . . . . . . . . . . . . . . 133
1.4 Draining and topping up coolant for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . 135
1.5 Fan shroud for radiator fan V7 and radiator fan right V35 for engines with code BKD, AZV
Removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.6 Removing and installing radiators for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . 138
1.7 Parts of the cooling system fitted to body for engines with code BMM . . . . . . . . . . . . . . . . 139
1.8 Parts of the cooling system engine side for engines with code BMM . . . . . . . . . . . . . . . . 141
1.9 Connection diagram for coolant hoses for engines with code BUD . . . . . . . . . . . . . . . . . . 143
1.10 Draining and topping up coolant for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . 143
1.11 Fan shroud for radiator fans V7 and V35 for engines with code BMM Removing and
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.12 Removing and installing the radiator for engines with code BMM . . . . . . . . . . . . . . . . . . . . 146
1.13 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.14 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.15 Check cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 Fuel tank with attached parts for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . 150
1.2 Fuel tank with attached parts for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . 152
1.3 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.4 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6 Remove and install the fuel tank for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . 157
1.7 Removing and installing fuel tank for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 159
1.8 Removing and installing the fuel delivery unit on vehicles with front-wheel drive . . . . . . . . 161
1.9 Removing and installing the fuel delivery unit on vehicles with four-wheel drive . . . . . . . . 162
1.10 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine - Edition 01.2018
ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1.11 Removing and installing fuel gauge sender G169 on vehicles with four-wheel drive. . . . . 169
1.12 Removing and installing the suction jet pump for vehicles with four-wheel drive . . . . . . . . 170
1.13 Removing and installing tandem pump, vehicles with engine code BKD, AZV . . . . . . . . . . 171
1.14 Removing and installing tandem pump, vehicles with engine code BMM . . . . . . . . . . . . . . 172
1.15 Inspecting a tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.16 inspecting fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1 Charge-air system with exhaust gas turbocharger - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . 184
1.1 Connection diagram for vacuum hoses for engines with code BKD, AZV . . . . . . . . . . . . . . 184
1.2 Connection diagram for valve block and vacuum sockets for engines with code BKD, AZV
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.3 Checking the vacuum actuator and tension rods for charge pressure regulation for engines
with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.4 Connection diagram for vacuum hoses for engines with code BUD . . . . . . . . . . . . . . . . . . 186
2 Charge-air system with exhaust gas turbocharger - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . 188
2.1 Removing and installing exhaust gas turbochargers for engines with code BKD, AZV . . . . 188
2.2 Removing and installing charge air cooling parts for engines with code BKD, AZV . . . . . . 191
2.3 Removing and installing the exhaust gas turbocharger for engines with code BMM . . . . . . 193
2.4 Removing and installing charge air cooling parts for engines with code BMM . . . . . . . . . . 196
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.6 Hose connections with quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.7 Checking the charge-air system for leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1 Repairing Diesel Direct Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.1 Installation locations for engines with code BKD, AZV - overview . . . . . . . . . . . . . . . . . . . . 202
1.2 Intake manifold - summary of components for engines with code BKD, AZV . . . . . . . . . . 205
1.3 Wiring harness for unit injectors and glow plugs - summary of components for engines with
code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.4 Removing and installing the wiring harness for unit injectors and glow plugs for engines with
code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.5 Removing and installing the air filter for engines with code BKD, AZV . . . . . . . . . . . . . . . . 208
1.6 Repairing unit injectors for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.7 Removing and installing unit injectors for engines with code BKD, AZV . . . . . . . . . . . . . . 210
1.8 Replacing the O-rings of the unit injector for engines with code BKD, AZV . . . . . . . . . . . . 215
1.9 Installation locations for engines with code BMM - overview . . . . . . . . . . . . . . . . . . . . . . . . 216
1.10 Intake manifold - summary of components for engines with code BMM . . . . . . . . . . . . . . 219
1.11 Removing and installing the air filter for engines with code BMM . . . . . . . . . . . . . . . . . . . . 220
1.12 Repairing unit injectors for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.13 Removing and installing unit injectors for engines with code BMM . . . . . . . . . . . . . . . . . . 221
1.14 Replacing the O-rings of the unit injector for engines with code BMM . . . . . . . . . . . . . . . . 225
1.15 Removing and installing the engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.1 Summary of components for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . 229
1.2 Summary of components for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.3 Exhaust system for vehicles with four-wheel drive - Summary of components . . . . . . . . . . 233
1.4 Removing and installing pre-exhaust pipe with diesel particle filter . . . . . . . . . . . . . . . . . . 234
1.5 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine - Edition 01.2018
Contents iii

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1.6 Align exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.7 Inspecting the exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.1 Removing and installing exhaust gas recirculation system parts for engines with code BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.2 Summary of components - radiator for exhaust gas recirculation system for engines with code
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.3 Checking the mechanical exhaust gas recirculation valve for engines with code BKD, AZV
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.4 Function of the exhaust gas recirculation radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.5 Checking the change-over for exhaust gas recirculation radiator for engines with code BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.6 Removing and installing the radiator for exhaust gas recirculation for engines with code BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.7 Removing and installing the exhaust gas recirculation system for engines with code BMM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2.8 Summary of components - radiator for exhaust gas recirculation system for engines with code
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.9 Checking the change-over for exhaust gas recirculation radiator for engines with code
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.10 Removing and installing the exhaust gas recirculation radiator for engines with code BMM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.11 Connection diagram for exhaust recirculation vacuum hoses for engines with code BMM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.1 Removing and installing the glow plugs for engines with code BKD, AZV . . . . . . . . . . . . . . 250
1.2 Checking the glow plugs for engines with code BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . 250
1.3 Removing and installing the glow plugs for engines with code BMM . . . . . . . . . . . . . . . . . . 250
1.4 Checking the glow plugs for engines with code BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine - Edition 01.2018
iv Contents

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00 – Technical data
1 Technical data
(SRL001190; Edition 01.2018)
1.1 Engine number
The engine number (“engine identification characters” and “serial
number”) is located at the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is attached to the timing belt guard.
The engine identification characters are also indicated on the ve‐
hicle data sticker.
1.2 Engine characteristics
Engine codes BKD AZV BMM
Manufactured 05:04 ► 10:04 ► 12:05 ►
Emission standards conforming to EU4 EU4 EU4
Displacement l 1.968 1.968 1.968
Output kW at rpm 103/4000 100/4000 103/4000
Torque Nm at rpm 320/1750 - 2500 320/1750 - 2500 320/1750 - 2500
Bore ∅ mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Number of valves per cylinder 4 4 2
Compression ratio 18.5 : 1 18.5 : 1 18.5 : 1
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes
Exhaust gas recirculation with radiator yes yes yes
Turbocharging yes yes yes
Charge air cooler yes yes yes
Diesel particle filter no no yes
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1. Technical data 1

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01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the “Vehicle self-diagnosis”, “Measuring method” and
“Fault finding” ⇒ Vehicle diagnostic tester.
1.2 Additional instructions when undertak‐
ing assembly work on the air-condition‐
ing system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐
tem.
Note
To avoid causing damage to the condenser and to the refrigerant
lines and hoses make sure the lines and hoses are not over-ex‐
tended, kinked or bent.
Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit:
– Unscrew the retaining clip(s) on the refrigerant lines.
– Remove V-ribbed belt ⇒ page 23 .
– Remove AC compressor from the bracket for auxiliary units
⇒ page 23 .
– Mount the air conditioning compressor and the condenser in
such a way that the refrigerant lines/hoses are not under ten‐
sion.
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2 Rep. gr.01 - Self-diagnosis

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1.3 Safety precautions when working on
fuel supply system
WARNING
♦ On vehicles with engine with unit injectors, the tempera‐
ture of the fuel lines or of the fuel can be up to 100 °C in
an extreme case. Let the fuel cool down before opening
the lines, as otherwise there is a high risk of burning.
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
♦ Fuel pump is activated by switching on ignition and via driver
door contact switch. Before opening the fuel system and for
reasons of safety, if the battery is not disconnected, the con‐
nector -arrow- must be disconnected from the fuel delivery
unit.
WARNING
When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
When removing and installing the fuel gauge sender from a full or
partly filled fuel tank, pay attention to the following:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.4 Safety precautions when working on the
diesel direct injection system
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.
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1. Self diagnosis, safety measures, cleanliness regulations and directions 3

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WARNING
Secure the test and measuring devices to the rear seat and
operate from that position.
Observe the following points to prevent injury to persons and/or
damage to the injection and preheating system:
♦ Ignition must be switched off before disconnecting and re-
connecting the wires of the injection and preheating system as
well as of the test equipment.
♦ If the engine should be run at the starter speed without it ac‐
tually igniting, then separate the central plug connection for
the unit injector at the cylinder head.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Switch off the ignition before connecting or disconnecting the
battery as this could otherwise damage the diesel direct injec‐
tion system control unit.
♦ When disconnecting and reconnecting the battery, carry out
additional operations ⇒ Electrical System ⇒ Rep. gr. 27 .
1.5 Regulations concerning cleanliness
when working on the fuel supply/fuel in‐
jection system
When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme‐
diately any hoses which have suffered damage.
1.6 Regulations concerning cleanliness
when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Use lint-
free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
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4 Rep. gr.01 - Self-diagnosis

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♦ Only install clean parts: remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
1.7 General instructions for charge air sys‐
tem
WARNING
When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger
is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, the following tasks must be performed:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all the air guides and the charge air cooler for for‐
eign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight, check ⇒ page 199 .
♦ Replace self-locking nuts.
♦ Hose connections and hoses for the charge air system must
be free of oil and grease before being installed. Only seals and
sealing surfaces of the quick couplings are coated with oil
⇒ page 198 .
♦ Observe markings on the hoses and components.
♦ All hose connections of the charge air system are secured with
spring strap clamps or push-fit couplings.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Assembly of hose connections with push-fit couplings
⇒ page 198 .
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1. Self diagnosis, safety measures, cleanliness regulations and directions 5

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♦ Before screwing down the oil feed line, fill the exhaust turbo‐
charger via the connection fitting with engine oil.
♦ To ensure the oil supply to the exhaust gas turbocharger,
leave the engine running for about 1 minute after installing the
exhaust gas turbocharger.
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6 Rep. gr.01 - Self-diagnosis

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10 – Removing and installing engine
1 Removing and installing engine
1.1 Removing engine
Special tools and workshop equipment required
♦ Catch pan for workshop cranes , e.g. -VAS 6208-
♦ Engine/gearbox jack , e.g. - V.A.G 1383 A-
♦ Engine mount - T10012-
♦ Workshop crane , e.g. -VAS 6100-
♦ Double ladder , e.g. -VAS 5085 -
♦ Hose clamps up to ∅ 25 mm - MP7-602 (3094) -
♦ Pliers for spring-type clips
– Enquire the event memories of all control units prior to engine
removal ⇒ Vehicle diagnostic tester.
Note
♦ The engine is removed downwards together with the gearbox.
♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
Caution
When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
Observe all safety measures and notes for assembly work on the
fuel supply and injection system, at the charge air system and
observe as well the rules for cleanliness ⇒ page 2 .
– Remove engine cover ⇒ page 13 .
– Before disconnecting the battery, if necessary remove the
adapter for the anti-theft wheel bolts from the luggage com‐
partment.
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1. Removing and installing engine 7

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WARNING
Observe necessary measures when disconnecting the battery
⇒ Electrical System ⇒ Rep. gr. 27 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐
trical System ⇒ Rep. gr. 27 .
– Remove plenum chamber cover and bulkhead plenum cham‐
ber ⇒ Body Work ⇒ Rep. gr. 66 .
– Remove air filter with air mass meter, air intake hose and suc‐
tion hose.
♦ Vehicles with engine code BKD, AZV: ⇒ page 208
♦ Engine code BMM: ⇒ page 220
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
gr. 27 .
– Slacken the screw for the front right drive shaft only by maxi‐
mum 90°, otherwise the wheel bearing may be damaged.
– Remove both front wheels ⇒ Chassis ⇒ Rep. gr. 44 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
– Remove bottom part of right wheelhouse liner ⇒ Body Work
⇒ Rep. gr. 66 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. gr. 40 .
– Unscrew left drive shaft from gearbox flange.
– Unscrew the nut from the left coupling rod -2- and press off the
coupling rod from the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.
– If present, unscrew coupling rod from front left vehicle level
sensor - G78- .
– Turn the steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheelhouse.
– Insert a pin screw in the suspension arm in order to stabilize
the steering joint.
WARNING
When opening the coolant expansion reservoir, hot steam or
hot coolant may escape. Cover the cap with a cloth and open
carefully.
– Drain coolant
♦ Vehicles with engine code BKD, AZV: ⇒ page 135
♦ Engine code BMM: ⇒ page 143
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8 Rep. gr.10 - Removing and installing engine

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– Detach coolant hose, fuel intake hose -2- and fuel return-flow
hose -1- from pipes at cylinder head.
Vehicles up to 08.05
– Unlatch fuse, remove fuel filter upwards from bracket -arrow-
with its connected lines, and place to the side.
Vehicles as of 08.05
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1. Removing and installing engine 9

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– Release screw -1- by one turn.
– Release screw -2- and nut -3-.
– Take out fuel filter with connected hoses and lay to the side.
Continued for all vehicles
– Remove V-ribbed belt ⇒ page 23 .
– Remove alternator ⇒ Electrical System ⇒ Rep. gr. 27 .
Vehicles with air conditioning
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐
tem.
Note
In order to avoid damage to the AC compressor as well as to the
refrigerant lines and hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.
– Remove AC compressor from the bracket for auxiliary units
⇒ page 23 .
– Tie up removed AC compressor with connected refrigerant
hoses to the body.
Vehicles with auxiliary heating
– Disconnect the necessary connections at the coolant pipes
and at the coolant shut-off valve of heating system - N279- .
– Only remove long exhaust pipe of auxiliary heater ⇒ Heating,
air conditioning ⇒ Rep. gr. 82 ,
Continued for all vehicles
– Remove charge air hoses and charge air pipe between engine
and charge air cooler:
♦ Motor code BKD, AZV: ⇒ page 191
♦ Engine code BMM: ⇒ page 196
Caution
Shut off the openings of the charge air cooler, e.g. with a clean
piece of foam, so that no coolant can get in.
– Remove fan shroud and radiator.
♦ Motor code BKD, AZV: ⇒ page 138
♦ Engine code BMM: ⇒ page 146
– Remove holder of the wire for oil level and oil temperature
sender - G266- from assembly carrier.
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10 Rep. gr.10 - Removing and installing engine

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– First, unscrew the screw -1-.
– Then unscrew screws -2- and -3- and remove the pendulum
support.
Vehicles with four-wheel drive
– Remove assembly carrier without steering gear ⇒ Chassis ⇒
Rep. gr. 40 .
– Remove propshaft from gearbox ⇒ Gearbox ⇒ Rep. gr. 39 .
Continued for all vehicles
Caution
The decoupling element in the pre-exhaust pipe should not be
bent by more than 10° - risk of damage.
– Remove the pre-exhaust pipe from the exhaust turbocharger
⇒ page 229 .
– Unlatch the fuse and disconnect the front plug from the engine
control unit ⇒ page 227 .
– Release duct for engine wiring harness -arrow- and pull out
upwards.
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1. Removing and installing engine 11

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– Open the cable guides -arrows-, remove the engine wiring
harness and place down to the side.
– Release all remaining plugs at engine and gearbox and lay
aside the relevant lines.
Note
To release the plug of the engine speed sensor - G28- , push
down on the plug with a screwdriver while lifting the release button
with a thin wire hook.
– Detach all connecting and vacuum hoses from the engine as
well as the coolant hoses.
Vehicles fitted with a manual gearbox
– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
gr. 34 .
– Remove pressure line from breather/slave cylinder ⇒ Gearbox
⇒ Rep. gr. 30 .
WARNING
After separating the hydraulic line, do not operate the clutch
pedal.
Vehicles with automatic gearbox
– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
gr. 34 .
Continued for all vehicles
– Screw engine mount - T10012- to the cylinder block with nut
-2- and screw -1- to 20 Nm.
– Insert engine/gearbox jack - V.A.G 1383 A- in the engine
mount and slightly raise.
WARNING
Use double ladder to release the screws for the engine/gear‐
box mounting.
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12 Rep. gr.10 - Removing and installing engine

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– Successively release screws for engine mounting -arrows-.
– Successively release screws for gearbox mounting -arrows-.
Note
♦ Check whether all hose and line connections between engine,
gearbox and body are released.
♦ When lowering carefully guide the engine with the gearbox, in
order to avoid damage.
– Carefully lower engine with gearbox.
– Remove the gearbox from the engine ⇒ gearbox ⇒ Rep. gr.
34 .
1.1.1 Removing and installing engine trim
panel
Removing
Vehicles with engine code BKD, AZV
– Remove dipstick -1- from dipstick guide.
– Lift engine cover at the sides -arrows 2- and pull out towards
the front -arrow 3-.
– Insert the dipstick into the dipstick guide so that no parts fall
into the opening.
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1. Removing and installing engine 13

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Vehicles with engine code BMM
– Remove outer -1- and inner -2- engine cover by pulling evenly
upwards.
Installing
Note
On vehicles with engine code BKD, AZV, the oil dipstick must be
pulled out of the dipstick guide before installation and pushed
back into the oil dipstick guide after installation.
Caution
Before installing the engine cover, check the correct installa‐
tion position of the 4 fastening elements (ball sockets). Put
them back in the correct positions if necessary. Otherwise this
can lead to damage to the engine cover.
– If necessary, press the ball sockets into the correct positions.
– Place the engine cover onto the fixing points and press it into
the catches.
1.2 Securing the engine to the assembly
stand
Special tools and workshop equipment required
♦ Lifting device - MP 9-201 (2024A)-
♦ Engine mount - MP 1-202 (VW 540)-
♦ Hook - MP 1-202/10-
♦ Bushing - T30010 (VW 540/1B)-
♦ Assembly stand - MP 9-101-
♦ Workshop crane , e.g. -VAS 6100-
Work procedure
• Separate engine from gearbox.
Octavia II 2004 ➤ , Octavia II 2010 ➤
2.0/100; 103 kW TDI PD Engine - Edition 01.2018
14 Rep. gr.10 - Removing and installing engine